Engine Controls - 4.3L - Introduction (2 of 2): Removal & Installation Chevrolet Silverado 1500

Powertrain Control Module (PCM) Replacement

Service of the powertrain control module (PCM) should consist of either replacement of the PCM, or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the PCM to be replaced, the replacement PCM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM.

Removal Procedure

Scheme 288

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Scheme 290

1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-238198-S11373134242006072400000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-238198-S42388157252006072400000) in Engine Electrical.
3. Release the PCM cover mounting tabs.
4. Release the PCM cover from the mounting brackets.
5. Remove the PCM cover.
6. Loosen the PCM electrical connector bolts (2). NOTE: Refer to «PCM AND ESD NOTICE»(ref-238188-S28243145932006072400000) in Cautions and Notices. NOTE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector.
7. Disconnect the PCM electrical connectors.
8. Release the spring latch from the PCM.
9. Release the PCM mounting tabs from the PCM.
10. Remove the PCM.

Installation Procedure

1. Install the PCM. Ensure that the mounting tabs are engaged.
2. Secure the spring latch to the PCM.
3. Connect the PCM electrical connectors. NOTE: Refer to «Fastener Notice»(ref-238188-S13145861262006072400000) in Cautions and Notices.
4. Tighten the PCM electrical connector bolts (2). Tighten: Tighten the bolts to 8 N.m (71 lb in).
5. Install the PCM cover. Ensure the mounting tabs are engaged into the mounting holes in the cover.
6. If a NEW PCM was installed, program the PCM. Refer to «Control Module References»(ref-238179-S31191948712006072400000) in Computer/Integrating Systems.

Note. Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage.

Note. Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.

Scheme 291

1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent. NOTE: Refer to «FASTENER NOTICE»(ref-246412-S41332073762006122100000) in Cautions and Notices.
2. Install the ECT sensor. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
3. Connect the ECT sensor electrical connector (5).
4. Fill the cooling system, if necessary. Refer to «Draining and Filling Cooling System (w/RPO HP2)»(ref-238207-S13164738462006072400000) or «Draining and Filling Cooling System (w/o RPO HP2)»(ref-238207-S02564800892006072400000) in Engine Cooling.

Scheme 292

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Scheme 294

1. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (4).
2. Loosen the air cleaner outlet duct clamp at the MAF/IAT sensor.
3. Remove the air cleaner outlet duct from the MAF/IAT sensor.
4. Loosen the MAF/IAT sensor clamp at the air cleaner box.
5. Remove the MAF/IAT sensor.

1. Install the MAF/IAT sensor. NOTE: Refer to «FASTENER NOTICE»(ref-246412-S41332073762006122100000) in Cautions and Notices.
2. Tighten the MAF/IAT sensor clamp at the air cleaner box. Tighten: Tighten the clamp to 4 N.m (35 lb in).
3. Install the air cleaner outlet duct to the MAF/IAT sensor.
4. Tighten the air cleaner outlet duct clamp at the MAF/IAT sensor. Tighten: Tighten the clamp to 4 N.m (35 lb in).
5. Connect the MAF/IAT sensor electrical connector (4).

Scheme 295

1. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (2).
2. Using a slight rocking motion, while pulling straight up, remove the MAP sensor.
3. Inspect the MAP sensor seal for damage, replace the seal, if necessary.

Scheme 296

1. Install a NEW MAP sensor seal, if necessary.
2. Install the MAP sensor.
3. Connect the MAP sensor electrical connector (2).

Scheme 297

Scheme 298

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
2. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to «HEATED OXYGEN AND OXYGEN SENSOR NOTICE»(ref-238188-S37340978552006072400000) in Cautions and Notices.
3. Disconnect the heated oxygen sensor (HO2S) electrical connector (1).
4. Remove the bank 1 HO2S (1).

1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to «FASTENER NOTICE»(ref-246412-S41332073762006122100000) in Cautions and Notices.
2. Install the bank 1 HO2S (1). Tighten: Tighten the sensor to 42 N.m (31 lb ft).
3. Connect the HO2S electrical connector (1).
4. Connect the CPA retainer.
5. Lower the vehicle.

Scheme 299

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Scheme 301

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
2. Remove the heated oxygen sensor (HO2S) connector from the crossmember, if equipped with a manual transmission and 2-wheel drive (2WD).
3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to «HEATED OXYGEN AND OXYGEN SENSOR NOTICE»(ref-238188-S37340978552006072400000) in Cautions and Notices.
4. Disconnect the HO2S electrical connector from the harness (2).
5. Remove the HO2S connector from the crossmember, if equipped with a automatic transmission and 2WD.
6. Disconnect the CPA retainer.
7. Disconnect the HO2S electrical connector from the harness.
8. Remove the HO2S connector from the crossmember, if equipped with 4-wheel drive (4WD).
9. Disconnect the CPA retainer.
10. Disconnect the HO2S electrical connector from the harness.
11. Remove the bank 1 HO2S (2).

1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to «FASTENER NOTICE»(ref-246412-S41332073762006122100000) in Cautions and Notices.
2. Install the bank 1 HO2S (2). Tighten: Tighten the sensor to 42 N.m (31 lb ft).
3. Connect the HO2S electrical connector to the harness.
4. Connect the CPA retainer.
5. Install the HO2S connector to the crossmember, if equipped with 4WD.
6. Connect the HO2S electrical connector to the harness.
7. Connect the CPA retainer.
8. Install the HO2S connector to the crossmember, if equipped with a automatic transmission and 2WD.
9. Connect the HO2S electrical connector to the harness (2).
10. Connect the CPA retainer.
11. Install the HO2S connector to the crossmember, if equipped with a manual transmission and 2WD.
12. Lower the vehicle.

Scheme 302

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
2. Remove the clip securing the heated oxygen sensor (HO2S) to the engine harness.
3. Remove the HO2S from the harness clip.
4. Remove the connector position assurance (CPA) retainer. NOTE: Refer to «HEATED OXYGEN AND OXYGEN SENSOR NOTICE»(ref-238188-S37340978552006072400000) in Cautions and Notices.
5. Disconnect the HO2S electrical connector.
6. Remove the bank 2 HO2S (1).

1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to «FASTENER NOTICE»(ref-246412-S41332073762006122100000) in Cautions and Notices.
2. Install the bank 2 HO2S (1). Tighten: Tighten the sensor to 42 N.m (31 lb ft).
3. Connect the HO2S electrical connector.
4. Install the CPA retainer.
5. Install the HO2S from the harness clip.
6. Install the clip securing the HO2S to the engine harness.
7. Lower the vehicle.

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
2. Remove the connector position assurance (CPA) retainer. NOTE: Refer to «HEATED OXYGEN AND OXYGEN SENSOR NOTICE»(ref-238188-S37340978552006072400000) in Cautions and Notices.
3. Disconnect the HO2S electrical connector.
4. Remove the bank 2 HO2S (2).

1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to «FASTENER NOTICE»(ref-246412-S41332073762006122100000) in Cautions and Notices.
2. Install the bank 2 HO2S (2). Tighten: Tighten the sensor to 42 N.m (31 lb ft).
3. Connect the HO2S electrical connector.
4. Install the CPA retainer.
5. Lower the vehicle.

Scheme 303

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-238194-S05547419412006072400000) .
2. Disconnect the throttle position (TP) sensor electrical connector (1).
3. Remove the TP sensor screws.
4. Remove the TP sensor.

Scheme 304

1. Install the TP sensor. Align the TP sensor with the throttle shaft.
2. Install the TP sensor screws. Tighten: Tighten the screws to 2 N.m (18 lb in).
3. Connect the TP sensor electrical connector (1).
4. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-238194-S05547419412006072400000) .

Scheme 305

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Scheme 307

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-238194-S05547419412006072400000) .
2. Disconnect the idle air control (IAC) valve electrical connector (2).
3. Remove the IAC valve screws.
4. Remove the IAC valve and O-ring seal.

1. Install the accelerator cable through the front of dash. Snap the accelerator cable cover tangs (1) through the front of dash.
2. Install the accelerator cable through the slot in the accelerator pedal lever.
3. Seat the accelerator cable retainer (3) into the accelerator pedal lever (2).
4. Install the driver side knee bolster. Refer to «Knee Bolster Replacement»(ref-238186-S18945448682006072400000) in Instrument Panel, Gages, and Console.
5. Connect the accelerator cable to the accelerator control bracket.
6. Connect the accelerator cable to the engine bracket.
7. Install the accelerator cable slug to the throttle body pulley.
8. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-238194-S05547419412006072400000) .

1. Remove the drive side knee bolster. Refer to «Knee Bolster Replacement»(ref-238186-S18945448682006072400000) in Instrument Panel, Gages, and Console.
2. Unseat the accelerator cable retainer (3) from the accelerator pedal lever (2).
3. Remove the end bushing retaining clips.
4. Remove the end bushings from the pivot shaft.
5. Remove the accelerator pedal.

1. Install the accelerator pedal.
2. Install the end bushings to the pivot shaft.
3. Install the end bushing retaining clips.
4. Install the accelerator cable through the slot in the accelerator pedal lever.
5. Seat the retainer (3) in the accelerator pedal lever (2).
6. Inspect for the following: Complete throttle opening and closing with no binding Proper carpet fit under the accelerator pedal
7. Install the driver side knee bolster. Refer to «Knee Bolster Replacement»(ref-238186-S18945448682006072400000) in Instrument Panel, Gages, and Console.

Scheme 308

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Scheme 313

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-238194-S05547419412006072400000) .
2. Remove the air cleaner outlet resonator stud.
3. Remove the cruise control cable from the throttle pulley.
4. Remove the cruise control cable from the engine bracket.
5. Remove the accelerator control cable from the accelerator control bracket.
6. Remove the accelerator control cable from the engine bracket.
7. Remove the accelerator control cable slug from the throttle pulley.
8. Remove the accelerator control cable bracket nuts.
9. Remove the accelerator control cable bracket with the cables attached, from the throttle body.
10. Position and secure the bracket and cables out of the way.
11. Disconnect the following electrical connectors: Throttle position (TP) sensor (1) Idle air control (IAC) valve (2)
12. Remove the throttle body studs.
13. Remove the throttle body.
14. Remove and discard the throttle body seal.

1. Install a NEW throttle body seal and the throttle body.
2. Install the throttle body studs. Tighten: Tighten the studs to 9 N.m (80 lb in).
3. Connect the following electrical connectors: TP sensor (1) IAC valve (2)
4. Position the bracket and cables.
5. Install the accelerator control cable bracket with the cables attached, to the throttle body.
6. Install the accelerator control cable bracket nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
7. Install the accelerator control cable slug to the throttle pulley.
8. Install the accelerator control cable to the engine bracket.
9. Install the accelerator control cable to the accelerator control bracket.
10. Install the cruise control cable to the engine bracket.
11. Install the cruise control cable to the throttle pulley.
12. Install the air cleaner outlet resonator stud. Tighten: Tighten the stud to 10 N.m (89 lb in).
13. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-238194-S05547419412006072400000) .

1. Remove the fuel rail pressure fitting cap.
2. Connect the J 34730-1A to the fuel pressure valve. See «Special Tools»(ref-238194-S31387655202006072400000) . Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage.
3. Install the bleed hose on J 34730-1A into an approved container. See «Special Tools»(ref-238194-S31387655202006072400000) .

1. Remove the bleed hose on the J 34730-1A from the approved container. See «Special Tools»(ref-238194-S31387655202006072400000) .
2. Remove the shop towel from around the fitting and discard into an approved container.
3. Disconnect the J 34730-1A from the fuel pressure valve. See «Special Tools»(ref-238194-S31387655202006072400000) .
4. Install the fuel rail pressure fitting cap.

Scheme 314

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Scheme 317

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-238175-S31489294622006072400000) .
2. Using compressed air, blow any dirt or debris from around the quick connect fitting.
3. Squeeze the plastic quick connect fitting release tabs together to disengage the quick connect fitting. (This step applies to Bartholomew style fittings ONLY)
4. Squeeze where indicated by the arrows on both sides of the plastic ring to disengage the quick connect fitting.
5. Squeeze where indicated by the arrows on both sides of the plastic ring to disengage the quick connect fitting.
6. Pull the quick connect fitting connection apart.

Scheme 318

Scheme 319

1. Apply a few drops of clean engine oil to the male connection end.
2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs to snap into place.
3. Once installed, pull on both sides of the quick-connect fittings in order to make sure the connection is secure.

Scheme 320

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Scheme 323

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-238194-S00239582142006072400000) .
2. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure»(ref-238194-S39186618882006072400000) .
3. Remove the fuel tank fill pipe. Refer to «Filler Tube Replacement»(ref-238194-S24274468062006072400000) .
4. Remove the EVAP canister vent solenoid. Refer to «Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement»(ref-238194-S35144098472006072400000) .
5. Remove the fuel tank shield bolts, if equipped.
6. Remove the fuel tank shield, if equipped.
7. Disconnect the fuel feed and EVAP lines. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-238194-S25639481892006072400000) .
8. Cap the fuel and EVAP lines in order to prevent possible system contamination.
9. Place a suitable adjustable jack under the fuel tank.
10. Remove the fuel tank strap bolts.
11. Remove the fuel tank straps.
12. Lower the fuel tank half way. When lowering the tank, ensure that the fill neck on the tank does not get hung up on the harness.
13. Disconnect the electrical harness clip at the frame crossmember.
14. Lower the fuel tank until the electrical connections are accessible.
15. Disconnect the fuel pressure sensor electrical connector (1).
16. Disconnect the fuel sending unit electrical connector (2), perform the following: Disengage the gray retainer. Push down the black clip. Disconnect the connector.
17. Completely lower the fuel tank.
18. With the aid of an assistant, place the fuel tank in a suitable work area.
19. If necessary, disconnect and remove the fuel feed line (1) from the sending unit and retaining clips.
20. If necessary, disconnect and remove the EVAP purge line (2) from the retaining clips.
21. If necessary, disconnect and remove the EVAP fuel level vent valve (FLVV) line from the FLVV, sending unit, and retaining clips.
22. If necessary, remove the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-238194-S36484030972006072400000) .

Scheme 324

1. If necessary, install the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-238194-S36484030972006072400000) .
2. If necessary, install and connect the EVAP FLVV line to the FLVV, sending unit, and retaining clips.
3. If necessary, install and connect the EVAP purge line (2) to the retaining clips.
4. If necessary, install and connect the fuel feed line (1) to the sending unit and retaining clips.
5. With the aid of an assistant, place the fuel tank onto the adjustable jack.
6. Raise the fuel tank until the electrical connections can be made.
7. Connect the fuel sending unit (2) and pressure sensor (1) electrical connectors.
8. Completely raise the fuel tank. When raising the tank, ensure that the fill neck on the tank goes over the harness.
9. Install the fuel tank straps. NOTE: Refer to «Fastener Notice»(ref-238188-S13145861262006072400000) in Cautions and Notices.
10. Install the fuel tank strap bolts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
11. Remove the adjustable jack from under the fuel tank.
12. Remove the caps from the fuel and EVAP lines.
13. Connect the fuel feed and EVAP lines. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-238194-S25639481892006072400000) .
14. If necessary, install the fuel tank shield.
15. If necessary, install the fuel tank shield bolts. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
16. Install the EVAP canister vent solenoid. Refer to «Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement»(ref-238194-S35144098472006072400000) .
17. Install the fuel tank fill pipe. Refer to «Filler Tube Replacement»(ref-238194-S24274468062006072400000) .
18. Refill the fuel tank.
19. Install the fuel cap.
20. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-238198-S11373134242006072400000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-238198-S42388157252006072400000) in Engine Electrical.
21. Perform the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.

Scheme 325

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-238194-S37597439622006072400000) .
2. Using a slight rocking motion, while pulling straight up, remove the fuel tank pressure sensor (1).

1. Install the fuel tank pressure sensor (1).
2. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-238194-S37597439622006072400000) .

Scheme 326

1. Remove the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-238194-S36484030972006072400000) .
2. Disconnect the fuel pump electrical connector.
3. Remove the fuel lever sensor electrical connector retaining clip.
4. Disconnect the fuel level sensor electrical connector.
5. Remove the fuel level sensor retaining clip.
6. Remove the fuel level sensor (1).

1. Install the fuel level sensor (1).
2. Install the fuel level sensor retaining clip.
3. Connect the fuel level sensor electrical connector.
4. Install the fuel lever sensor electrical connector retaining clip.
5. Connect the fuel pump electrical connector.
6. Install the sending unit. Refer to «Fuel Sender Assembly Replacement»(ref-238194-S36484030972006072400000) .

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Scheme 331

1. Remove the fuel tank filler housing to body TORX® screws (1) and pushpin retainer (2).
2. Remove the fuel tank filler housing to fuel tank fill pipe bolts.
3. Remove the fuel tank filler housing.
4. Raise and suitably support the vehicle half way. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
5. Remove the fuel tank fill pipe ground wire bolt (1).
6. Remove the fuel tank fill pipe ground wire (3) anti-rotation tab from the frame hole.
7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (2).
8. Open the axle vent hose clip on the fuel fill pipe bracket.
9. Remove the rear axle vent hose from the clip.
10. Loosen the fuel tank fill pipe clamp (1) at the fuel tank.
11. Disconnect the recirculation line from the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-238194-S25639481892006072400000) .
12. Remove the fuel tank fill pipe.
13. Cap the opening on the fuel tank in order to prevent possible system contamination.

1. Remove the cap from the opening on the fuel tank.
2. Install the fuel tank fill pipe.
3. Connect the recirculation line to the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-238194-S25639481892006072400000) . NOTE: Refer to «Fastener Notice»(ref-238188-S13145861262006072400000) in Cautions and Notices.
4. Tighten the fuel tank fill pipe clamp (1) at the fuel tank. Tighten: Tighten the clamp to 2.5 N.m (22 lb in).
5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
6. Close the axle vent hose clip.
7. Position the fuel tank fill pipe ground wire and chassis harness ground wire (2).
8. Install the fuel tank fill pipe ground wire (3) anti-rotation tab into the frame hole.
9. Install the fuel tank fill pipe ground wire bolt (1). Tighten: Tighten the bolt to 9 N.m (80 lb in).
10. Lower the vehicle.
11. Install the fuel tank filler housing.
12. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten: Tighten the screws to 2.3 N.m (20 lb in).
13. Install the fuel tank filler housing to body TORX® screws (1) and pushpin retainer (2). Tighten: Tighten the screws to 2.3 N.m (20 lb in).

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-238194-S37597439622006072400000) .
2. Disconnect the fuel line from the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-238194-S25639481892006072400000) .
3. Disconnect the evaporative emission (EVAP) line from the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-238194-S25639481892006072400000) .
4. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. See «Special Tools»(ref-238194-S31387655202006072400000) .
5. Remove the sending unit and seal. Discard the seal.
6. Clean the sending unit sealing surfaces. Turn the fuel sender lock ring in a counterclockwise direction.
7. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points.
8. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
9. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

1. Install the sending unit.
2. Use the J 45722 in order to install the fuel sender lock ring. See «Special Tools»(ref-238194-S31387655202006072400000) . Turn the fuel sender lock ring in a clockwise direction.
3. Connect the EVAP line to the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-238194-S25639481892006072400000) .
4. Connect the fuel line to the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-238194-S25639481892006072400000) .
5. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-238194-S37597439622006072400000) .

Scheme 332

Scheme 333

Scheme 334

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-238194-S05547419412006072400000) .
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-238194-S00239582142006072400000) .
3. Disconnect the fuel feed chassis pipe from the engine compartment feed pipe (1). Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-238194-S12173669922006072400000) .
4. Cap the fuel pipe in order to prevent possible fuel system contamination.
5. Remove the fuel pipe bracket nuts (510).
6. Remove the fuel pipe bracket (753).
7. Remove the fuel pipe bolt (509).
8. Pull straight up on the pipes in order to remove the pipe (700) from the fuel meter body.
9. Remove and discard the following components from the fuel meter body: Fuel seal retainers (1) Upper fuel seals (2) Spacer rings (3) Lower fuel seals (4)

1. Install the following NEW components to the fuel meter body: Lower fuel seals (4) Spacer rings (3) Upper fuel seals (2) Fuel seal retainers (1)
2. Apply a few drops of clean engine oil to the fuel pipe end.
3. Install the fuel pipes (700) to the fuel meter body.
4. Install the fuel pipe bracket (753).
5. Install the fuel pipe bracket nuts (510). NOTE: Refer to «Fastener Notice»(ref-238188-S13145861262006072400000) in Cautions and Notices.
6. Install the fuel pipe bolt (509). Tighten: Tighten the bolt to 6 N.m (53 lb in). Tighten the nuts to 3 N.m (27 lb in).
7. Remove the cap from the fuel pipe.
8. Connect the chassis fuel feed pipe to the engine compartment fuel pipe (1). Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-238194-S12173669922006072400000) .
9. Test the system for leaks using the following procedure: Turn the ignition ON, with the engine OFF for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
10. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-238194-S05547419412006072400000) .

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Scheme 339

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-238194-S00239582142006072400000) .
2. Disconnect the chassis fuel feed line at the engine fuel line (1). Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-238194-S12173669922006072400000) .
3. Disconnect the EVAP line (3). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-238194-S25639481892006072400000) .
4. Cap the engine fuel line (1), and EVAP line (3) in order to avoid possible system contamination.
5. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
6. Remove the fuel pipe bracket nut.
7. Remove the fuel pipe bracket from the bellhousing stud.
8. Remove the heated oxygen sensor (HO2S) sensor connector from the bracket.
9. Remove the fuel line clip from the bracket on the transmission.
10. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case.
11. Remove the clip from the bracket on the frame.
12. Remove the transfer case harness from the clip bracket.
13. Thoroughly wash all contaminants from around the EHCU.
14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM).
15. Disconnect the brake lines from the brake pressure modulator valve (BPMV).
16. Remove the bolts (4) attaching the EHCU bracket to the frame (5).
17. Remove the EHCU (1).
18. If equipped with 4WD, remove the torsion bar bracket. Refer to «Torsion Bar Replacement»(ref-238259-S42354176052006072400000) in Front Suspension.
19. Disconnect the fuel and EVAP lines at the fuel tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-238194-S25639481892006072400000) .
20. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination.
21. Remove the fuel and EVAP bundle clip nuts.
22. Remove the fuel and EVAP bundle.

1. Install the fuel and EVAP bundle. NOTE: Refer to «Fastener Notice»(ref-238188-S13145861262006072400000) in Cautions and Notices.
2. Install the fuel and EVAP bundle clip nuts. Tighten: Tighten the nuts to 12 N.m (106 lb in).
3. Remove the caps from the fuel and EVAP lines at the fuel tank.
4. Connect the fuel and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-238194-S25639481892006072400000) .
5. If equipped with 4WD, install the torsion bar bracket. Refer to «Torsion Bar Replacement»(ref-238259-S42354176052006072400000) in Front Suspension.
6. Install the EHCU (1).
7. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
8. Connect the brake lines to the BPMV. Tighten: Tighten the fittings to 25 N.m (18 lb ft).
9. Connect the chassis electrical harness connectors to the EBCM.
10. Install the transfer case harness to the clip bracket.
11. Install the clip to the bracket on the frame.
12. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case.
13. Install the fuel line clip to the bracket on the transmission.
14. Install the HO2S sensor connector to the bracket.
15. Install the fuel pipe bracket to the bellhousing stud.
16. Install the fuel pipe bracket nut. Tighten: Tighten the nut to 10 N.m (89 lb in).
17. Lower the vehicle.
18. Remove the caps from the engine fuel line (1) and EVAP line (3).
19. Connect the EVAP line (3). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-238194-S25639481892006072400000) .
20. Connect the chassis fuel feed line at the engine fuel line (1). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-238194-S25639481892006072400000) .
21. Install the fuel fill cap.
22. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-238198-S11373134242006072400000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-238198-S42388157252006072400000) in Engine Electrical.
23. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(ref-238194-S37597439622006072400000) .
2. Disconnect and remove the fuel feed line (1) from the sending unit and retaining clips.
3. Cap the fuel feed and evaporative emission (EVAP) openings in order to prevent possible fuel/EVAP system contamination.

1. Remove the caps from the fuel feed/return, and EVAP lines.
2. Install and connect the fuel feed (1) line to the sending unit and retaining clips.
3. Install the fuel tank. Refer to «Fuel Tank Replacement»(ref-238194-S37597439622006072400000) .

1. Remove the upper intake manifold. Refer to «Intake Manifold Replacement - Upper»(ref-238222-S18705452722006072400000) in Engine Mechanical-4.3L.
2. Remove and discard the fuel meter body seal.
3. Before removal, clean the fuel meter body with a spray type engine cleaner, such as GM X-30A, or equivalent, if necessary. Follow the package instructions. Do not soak the fuel meter body in liquid cleaning solvent.
4. Remove the injectors from the lower intake manifold bores. Lightly pull on the injector tube and using a small pocket screwdriver, remove the injector from the manifold.
5. Remove the MFI (multi-port flexible injection) fuel meter body from the MFI bracket

Scheme 340

1. Position the fuel tubes of the MFI fuel meter body in the forward position.
2. Install the MFI fuel meter body into the fuel meter body bracket on the lower intake manifold. Push down firmly to lock the fuel meter body into the fuel meter body bracket.
3. Insert the injectors in the following sequence into the correct injector bore in the lower manifold. Number 3 Number 5 Number 1 Number 2 Number 4 Number 6
4. Insure the electrical connectors on the injectors are positioned so that they do not interfere with each other and are pointing towards the center of the intake manifold. Rotate the electrical connectors inboard if necessary.
5. Lubricate the upper intake manifold O-ring on the fuel meter body with clean engine oil.
6. Install the upper intake manifold. Refer to «Intake Manifold Replacement - Upper»(ref-238222-S18705452722006072400000) in Engine Mechanical - 4.3L.
7. Tighten the fuel fill cap.
8. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-238198-S11373134242006072400000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-238198-S42388157252006072400000) in Engine Electrical.
9. Test for fuel leaks using the following procedure: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.

Scheme 341

1. Remove the upper intake manifold. Refer to «Intake Manifold Replacement - Upper»(ref-238222-S18705452722006072400000) .
2. Remove the fuel pressure dampener retaining clip (7).
3. Twist and pull the fuel pressure dampener (6) in order to remove the regulator from the housing using a shop towel to catch any spilled fuel.
4. Remove and discard the dampener O-ring seal (5).
5. Cover the fuel pressure dampener housing to prevent contamination from entering the fuel system.

1. Lubricate the NEW O-ring with clean engine oil.
2. Install the fuel pressure dampener O-ring seal (5).
3. Install the fuel pressure dampener (6).
4. Install the fuel pressure dampener retaining clip (7).
5. Install the upper manifold. Refer to «Intake Manifold Replacement - Upper»(ref-238222-S18705452722006072400000) .
6. Tighten the fuel fill cap.
7. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-238198-S11373134242006072400000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-238198-S42388157252006072400000) .
8. Inspect for leaks. Turn the ignition ON, for 2 seconds. Turn the ignition OFF, for 10 seconds. Turn the ignition ON. Inspect for fuel leaks.

1. Remove the fuel meter body. Refer to «Fuel Meter Body Assembly Replacement»(ref-238194-S10978867152006072400000) .
2. Remove the injector retainer lock nuts (4) and retainer (3).
3. While pulling the fuel injector downward, push with a small tip punch down between the injector terminals until the injector is removed.

1. Lubricate the NEW injector O-ring seals with clean engine oil.
2. Install the fuel injector (2) into the fuel meter body injector socket. NOTE: Refer to «Fastener Notice»(ref-238188-S13145861262006072400000) .
3. Install the injector retainer (3) and the injector retainer lock nuts (4). Tighten: Tighten the nuts to 3 N.m (27 lb in).
4. Install the fuel meter body. Refer to «Fuel Meter Body Assembly Replacement»(ref-238194-S10978867152006072400000) .

Scheme 342

Scheme 343

Scheme 344

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-238194-S05547419412006072400000) .
2. Disconnect the evaporative emission (EVAP) canister purge solenoid valve tube (1) from the valve (2).
3. Disconnect the purge solenoid electrical connector (1).
4. Remove the purge solenoid nut.
5. Remove the engine wiring harness bracket from the stud.
6. Remove the purge solenoid stud.
7. Remove the purge solenoid from the intake manifold.

1. Install the purge solenoid to the intake manifold. NOTE: Refer to «Fastener Notice»(ref-238188-S13145861262006072400000) in Cautions and Notices.
2. Install the purge solenoid stud. Tighten: Tighten the stud to 12 N.m (106 lb in).
3. Install the engine wiring harness bracket to the stud.
4. Install the purge solenoid nut. Tighten: Tighten the nut to 12 N.m (106 lb in).
5. Connect the purge solenoid electrical connector (1).
6. Connect the EVAP canister purge solenoid valve tube (1) to the valve (2).
7. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-238194-S05547419412006072400000) .

Scheme 345

Scheme 346

Scheme 347

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
2. Remove the harness clip from the canister vent solenoid (CVS) line.
3. Disconnect the CVS electrical connector.
4. If the vehicle is equipped with a 6 ft box, disconnect the EVAP CVS line from the canister.
5. Remove the CVS clip from the frame crossmember.
6. Push in the retainer and remove the CVS from the fuel tank clip.
7. If the vehicle is equipped with a 8 ft box, disconnect the EVAP CVS line from the canister.
8. Remove the CVS clip from the frame crossmember.
9. Push in the retainer and remove the CVS from the fuel tank clip.

1. If the vehicle is equipped with a 8 ft box, install the CVS to the fuel tank until the clip engages. IMPORTANT: On vehicles equipped with a 8 ft box, the CVS line is routed below the frame crossmember.
2. Install the CVS clip to the frame crossmember.
3. Connect the EVAP CVS line to the canister.
4. If the vehicle is equipped with a 6 ft box, install the CVS to the fuel tank until the clip engages. IMPORTANT: On vehicles equipped with a 6 ft box, the CVS line is routed above the frame crossmember.
5. Install the CVS clip to the frame crossmember.
6. Connect the EVAP CVS line to the canister.
7. Connect the CVS electrical connector.
8. Install the harness clip to the canister vent solenoid (CVS) line.
9. Lower the vehicle.

1. Disconnect the EVAP canister purge solenoid valve line at the valve.
2. Disconnect the EVAP canister purge solenoid valve line (3) from the chassis pipe.
3. Remove the EVAP canister purge solenoid valve tube.
4. Cap the EVAP purge valve and the chassis EVAP pipe in order to prevent possible EVAP system contamination.

1. Remove the caps from the EVAP purge valve and the chassis EVAP line.
2. Install the EVAP canister purge solenoid valve line.
3. Connect the EVAP canister purge solenoid valve line (3) to the chassis pipe.
4. Connect the EVAP canister purge solenoid valve tube to the valve.

Scheme 348

1. Remove the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(ref-238175-S02459278522006072400000) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(ref-238175-S02352285902006072400000) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(ref-238175-S19897563532006072400000) .
2. Remove the EVAP canister line (1). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-238175-S27762818972006072400000) .
3. Remove the EVAP canister purge line (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-238175-S27762818972006072400000) .
4. Cap the fuel and EVAP lines in order to prevent possible fuel/EVAP system contamination.

1. Remove the caps from the fuel and EVAP lines.
2. Install the EVAP canister purge line (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-238175-S27762818972006072400000) .
3. Install the EVAP canister line (1). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-238175-S27762818972006072400000) .
4. Install the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(ref-238175-S02459278522006072400000) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(ref-238175-S02352285902006072400000) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(ref-238175-S19897563532006072400000) .

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-238194-S00239582142006072400000) .
2. Disconnect the chassis fuel feed line at the engine fuel line (1). Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-238194-S12173669922006072400000) .
3. Disconnect the EVAP line (3). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-238194-S25639481892006072400000) .
4. Cap the engine fuel line (1), and EVAP line (3) in order to avoid possible system contamination.
5. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
6. Remove the fuel pipe bracket nut.
7. Remove the fuel pipe bracket from the bellhousing stud.
8. Remove the heated oxygen sensor (HO2S) sensor connector from the bracket.
9. Remove the fuel line clip from the bracket on the transmission.
10. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case.
11. Remove the clip from the bracket on the frame.
12. Remove the transfer case harness from the clip bracket.
13. Thoroughly wash all contaminants from around the EHCU.
14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM).
15. Disconnect the brake lines from the brake pressure modulator valve (BPMV).
16. Remove the bolts (4) attaching the EHCU bracket to the frame (5).
17. Remove the EHCU (1).
18. If equipped with 4WD, remove the torsion bar bracket. Refer to «Torsion Bar Replacement»(ref-238259-S42354176052006072400000) in Front Suspension.
19. Disconnect the fuel and EVAP lines at the fuel tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-238194-S25639481892006072400000) .
20. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination.
21. Remove the fuel and EVAP bundle clip nuts.
22. Remove the fuel and EVAP bundle.

1. Install the fuel and EVAP bundle. NOTE: Refer to «Fastener Notice»(ref-238188-S13145861262006072400000) in Cautions and Notices.
2. Install the fuel and EVAP bundle clip nuts. Tighten: Tighten the nuts to 12 N.m (106 lb in).
3. Remove the caps from the fuel and EVAP lines at the fuel tank.
4. Connect the fuel and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-238194-S25639481892006072400000) .
5. If equipped with 4WD, install the torsion bar bracket. Refer to «Torsion Bar Replacement»(ref-238259-S42354176052006072400000) in Front Suspension.
6. Install the EHCU (1).
7. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
8. Connect the brake lines to the BPMV. Tighten: Tighten the fittings to 25 N.m (18 lb ft).
9. Connect the chassis electrical harness connectors to the EBCM.
10. Install the transfer case harness to the clip bracket.
11. Install the clip to the bracket on the frame.
12. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case.
13. Install the fuel line clips to the brackets on the transmission.
14. Install the HO2S sensor connector to the bracket.
15. Install the fuel pipe bracket to the bellhousing stud.
16. Install the fuel pipe bracket nut. Tighten: Tighten the nut to 10 N.m (89 lb in).
17. Lower the vehicle.
18. Remove the caps from the engine fuel line (1) and EVAP line (3).
19. Connect the EVAP line (3). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-238194-S25639481892006072400000) .
20. Connect the chassis fuel feed line at the engine fuel line (1). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-238194-S25639481892006072400000) .
21. Install the fuel fill cap.
22. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-238198-S11373134242006072400000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-238198-S42388157252006072400000) in Engine Electrical.
23. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.

Scheme 349

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
2. Disconnect the EVAP canister vent solenoid (CVS) line from the EVAP canister.
3. Disconnect the fuel tank EVAP line from the canister.
4. Disconnect the canister EVAP line from the fuel bundle line.
5. Remove the EVAP canister nut.
6. Remove the EVAP canister with shield from the bracket.
7. If necessary, remove the EVAP canister from the shield, perform the following: Lift up the retaining clip on the bottom of the canister. Remove the canister from the shield.
8. If necessary, disconnect the EVAP lines from the canister.

1. If necessary, connect the EVAP lines to the canister.
2. If necessary, install the EVAP canister to the shield, perform the following: Install the canister to the shield. Ensure the retaining clip engages on the bottom of the canister.
3. Install the EVAP canister with shield to the bracket. NOTE: Refer to «Fastener Notice»(ref-238188-S13145861262006072400000) in Cautions and Notices.
4. Install the EVAP canister nut. Tighten: Tighten the nut to 25 N.m (18 lb ft).
5. Connect the canister EVAP line to the fuel bundle line.
6. Connect the fuel tank EVAP line to the canister.
7. Connect the EVAP CVS line to the canister.
8. Lower the vehicle.

Note. There are two procedures available to install the distributor. Use Installation Procedure 1 when the crankshaft has NOT been rotated from the original position. Use Installation Procedure 2 when any of the following components are removed: The intake manifold The cylinder head The camshaft The timing chain or sprockets The complete engine If the malfunction indicator lamp (MIL) turns on and DTC P1345 sets after installing the distributor, this indicates an incorrectly installed distributor. Engine damage or distributor damage may occur. Use Procedure 2 in order to install the distributor.

Scheme 350

Scheme 351

Scheme 352

Scheme 353

Scheme 354

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-238194-S05547419412006072400000) .
2. Disconnect the following electrical connectors: Camshaft position (CMP) sensor (2) Fuel pump/oil pressure sensor (3)
3. Remove the ignition coil wire from the ignition coil and distributor cap.
4. Remove the spark plug wires from the distributor cap. Twist each spark plug boot 1/2 turn. Pull only on the wire boot in order to remove the wire from the distributor cap.
5. Remove and discard the distributor cap screws.
6. Remove the distributor cap.
7. Using a grease pencil, mark the position of the rotor in relation to the distributor housing (1).
8. Also, mark the distributor housing and the intake manifold.
9. Remove the distributor hold down bolt.
10. Remove the distributor.
11. As the distributor is being removed, watch the rotor move in a counterclockwise direction about 42 degrees.
12. Note the position of the rotor segment.
13. Place a second mark on the base of the distributor (2). This will aid in achieving proper rotor alignment during distributor installation.

Installation Procedure 1

1. If installing a NEW distributor, place 2 marks on the new distributor housing in the same location as the marks on the original housing.
2. Align the rotor with the second mark (2).
3. Install the distributor.
4. Align the hole in the distributor hold-down clamp over the hole in the intake manifold.
5. As the distributor is being installed, observe the rotor moving in a clockwise direction about 42 degrees.
6. Once the distributor is completely seated, the rotor segment should be aligned with the mark on the distributor base (1).
7. Install the distributor hold down bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
8. Install the distributor cap.
9. Install NEW distributor cap screws. Tighten: Tighten the screws to 2.4 N.m (21 lb in).
10. Connect the following electrical connectors: CMP sensor (2) Fuel pump/oil pressure sensor (3)
11. Install the ignition coil wire to the ignition coil and distributor cap.
12. If the malfunction indicator lamp (MIL) is ON after installing the distributor, and diagnostic trouble code (DTC) P1345 is found, the distributor was installed incorrectly. Refer to «Installation Procedure 2»(ref-238194-S42082986622006072400000) .
13. If the MIL is not on, install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-238194-S05547419412006072400000) .

Installation Procedure 2

Scheme 355

Scheme 356

Scheme 357

1. Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer are aligned with the tabs on the engine front cover and the number 1 piston is at TDC of the compression stroke.
2. Align the white paint mark on the bottom stem of the distributor, with the pre-drilled indent hole in the bottom of the gear (3).
3. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1).
4. Using a long screwdriver, align the oil pump drive shaft to the drive tab of the distributor.
5. Guide the distributor into the engine. Ensure that the spark plug towers are perpendicular to the centerline of the engine.
6. Once the distributor is fully seated, the rotor segment should be aligned with the pointer cast into the distributor base. This pointer may have a 6 cast into it, indicating that the distributor is to be used on a 6 cylinder engine. If the rotor segment does not come within a few degrees of the pointer, the gear mesh between the distributor and the camshaft may be off a tooth or more. If this is the case, repeat the procedure again in order to achieve proper alignment.
7. Install the distributor hold down bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
8. Install the distributor cap.
9. Install NEW distributor cap screws. Tighten: Tighten the screws to 2.4 N.m (21 lb in).
10. Connect the following electrical connectors: CMP sensor (2) Fuel pump/oil pressure sensor (3)
11. Install the ignition coil wire to the ignition coil and distributor cap.
12. If the MIL is ON after installing the distributor, and DTC P1345 is found, the distributor has been installed incorrectly. Repeat installation procedure 2.
13. If the MIL is not on, install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-238194-S05547419412006072400000) .

Scheme 358

Scheme 359

Scheme 360

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-238194-S05547419412006072400000) .
2. Remove the ignition coil wire from the ignition coil and distributor cap.
3. Disconnect the following electrical connectors: Ignition coil (1) Ignition coil driver (2)
4. Remove the accelerator cable slug from the throttle lever.
5. Remove the cruise control cable from the throttle lever.
6. Remove the accelerator cable from the engine bracket.
7. Remove the cruise control cable from the engine bracket.
8. Remove the accelerator control cable bracket nuts.
9. Remove the accelerator control cable bracket with cables attached, from the throttle body.
10. Position and secure the bracket and cables out of the way.
11. Remove the accelerator cable bracket nuts and stud.
12. Remove the accelerator cable bracket.
13. Remove the ignition coil bracket studs.
14. Remove the ignition coil and bracket.
15. Remove the ignition coil bolts/nuts.
16. Remove the ignition coil from the brackets.

1. Install the brackets to either side of the ignition coil. NOTE: Refer to «FASTENER NOTICE»(ref-246412-S41332073762006122100000) in Cautions and Notices.
2. Install the ignition coil bolts/nuts. Tighten: Tighten the bolts/nuts to 3.5 N.m (31 lb in).
3. Place the ignition coil and bracket into position.
4. Install the ignition coil bracket studs. Tighten: Tighten the studs to 11 N.m (97 lb in).
5. Install the accelerator cable bracket.
6. Install the accelerator cable bracket nuts and stud. Tighten: Tighten the nuts/stud to 12 N.m (106 lb in).
7. Position the bracket and cables.
8. Install the accelerator control cable bracket with cables attached, to the throttle body.
9. Install the accelerator control cable bracket nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
10. Install the accelerator cable to the engine bracket.
11. Install the cruise control cable to the engine bracket.
12. Install the cruise control cable to the throttle lever.
13. Install the accelerator cable slug to the throttle lever.
14. Connect the following electrical connectors: Ignition coil (1) Ignition coil driver (2)
15. Install the ignition coil wire to the ignition coil and distributor cap.
16. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-238194-S05547419412006072400000) .

Scheme 361

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-238194-S05547419412006072400000) .
2. Disconnect the ignition coil driver electrical connector (3).
3. Remove ignition control module (2) screws.
4. Remove the ignition control module (2) and heat sink (3).

1. Position the ignition control module (2) and heat sink (3). NOTE: Refer to «FASTENER NOTICE»(ref-246412-S41332073762006122100000) in Cautions and Notices.
2. Install ignition control module (2) screws. Tighten: Tighten the screws to 3.5 N.m (31 lb in).
3. Connect the ignition coil driver electrical connector (3).
4. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(ref-238194-S05547419412006072400000) .

Note. If the boot to wire movement has occurred, the boot will give a false visual impression of being fully seated. Ensure that the boots have been properly assembled by pushing sideways on the installed boots. Failure to properly seat the terminal onto the spark plug will lead to wire core erosion and result in an engine misfire or crossfire condition, and possible internal damage to the engine.

1. Install the spark plug wire at the distributor.
2. Install the spark plug wire to each spark plug.
3. Install the wire to the wire separators. IMPORTANT: Wire routing must be kept intact during service and followed exactly when wires have been disconnected or replaced.
4. Inspect the wires for proper installation: Push sideways on each boot in order to inspect the seating. Reinstall any loose boot. Any time the spark plug wire or boot are installed on the spark plug, new dielectric grease needs to be applied inside the boot.

Scheme 362

Scheme 363

Scheme 364

Scheme 365

1. Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to «Ignition System Specifications»(ref-238175-S25986092952006072400000) for the correct spark plug.
2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling-Colder plug Pre-ignition causing spark plug and/or engine damage-Hotter plug
3. Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move.
4. Inspect the insulator (2) for flashover, carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground.
5. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4).
6. Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to «Ignition System Specifications»(ref-238175-S25986092952006072400000) . An excessively wide electrode gap can prevent correct spark plug operation. Inspect for the correct spark plug torque. Refer to «Ignition System Specifications»(ref-238175-S25986092952006072400000) . Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). Inspect for a broken or worn side electrode (3). Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. A loose center electrode (4) reduces the spark intensity. Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. Inspect for excessive fouling.
7. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation.

1. Ensure that the spark plug washer is positioned correctly.
2. Inspect the spark plug gap. Adjust the gap as needed. Specification: Spark plug gap: 1.524 mm (0.060 in) NOTE: Refer to «FASTENER NOTICE»(ref-246412-S41332073762006122100000) in Cautions and Notices.
3. Hand start the spark plug into the corresponding cylinder.
4. Tighten the spark plug. Tighten: For used heads, tighten the plug to 15 N.m (11 lb ft). For new aluminum heads, tighten the plug to 20 N.m (15 lb ft). For new iron heads, tighten the plug to 30 N.m (22 lb ft).

Scheme 366

Scheme 367

Scheme 368

Scheme 369

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) in General Information.
2. If equipped, remove the engine shield bolts.
3. Remove the engine shield.
4. Disconnect the CKP sensor electrical connector (5).
5. Remove the CKP sensor bolt.
6. Remove the CKP sensor.

1. If installing the old CKP sensor, install a NEW O-ring seal.
2. Lubricate the O-ring seal with clean engine oil.
3. Install the CKP sensor.
4. Install the CKP sensor bolt. Tighten: Tighten the bolt to 9 N.m (80 lb in).
5. Connect the CKP sensor electrical connector (5).
6. Install the engine shield.
7. Install the engine shield bolts. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
8. Perform the CKP system variation learn procedure. Refer to «CKP System Variation Learn Procedure»(ref-238194-S01351384412006072400000) .

Scheme 370

Scheme 371

Scheme 372

Scheme 373

Scheme 374

Scheme 375

1. Remove the ignition coil wire from the distributor.
2. Remove the spark plug wires from the distributor. Twist the spark plug wire boot 1/2 turn. Pull only on the boot or use a tool designed for this purpose in order to remove the wires from the distributor.
3. Disconnect the camshaft position (CMP) sensor electrical connector (2).
4. Remove the distributor cap screws.
5. Remove the distributor cap.
6. Remove the rotor screws.
7. Remove the rotor.
8. Align the square slot in the reluctor wheel with the CMP sensor.
9. Remove the CMP screws.
10. Remove the CMP sensor.

1. Insert the CMP sensor in the reluctor wheel slot.
2. Install NEW CMP screws. Tighten: Tighten the screws to 2.2 N.m (19 lb in).
3. Install the rotor.
4. Install NEW rotor screws. Tighten: Tighten the screws to 2 N.m (18 lb in).
5. Install the distributor cap.
6. Install NEW distributor cap screws. Tighten: Tighten the screws to 2.4 N.m (21 lb in).
7. Connect the CMP sensor electrical connector (2).
8. Connect the spark plug wires and ignition coil wire to the distributor.

Scheme 376

1. Remove the distributor. Refer to «Distributor Replacement»(ref-238194-S00024822292006072400000) .
2. Disconnect the knock sensor electrical connector (1).
3. Remove the knock sensor bolt (1).
4. Remove the knock sensor (2).

1. Install the knock sensor (2). NOTE: Refer to «Fastener Notice»(ref-238188-S13145861262006072400000) in Cautions and Notices.
2. Install the knock sensor bolt (1). Tighten: Tighten the bolt to 25 N.m (18 lb ft).
3. Connect the knock sensor electrical connector (1).
4. Install the distributor. Refer to «Distributor Replacement»(ref-238194-S00024822292006072400000) .

Scheme 377

1. Loosen the air cleaner outlet resonator clamp at the mass air flow/intake air temperature (MAF/IAT) sensor.
2. Remove the outlet resonator from the MAT/IAT sensor.
3. Loosen the air cleaner cover screws.
4. Remove the air cleaner cover.
5. Remove the air cleaner element.

Scheme 378

1. Insert the air cleaner element.
2. Install the air cleaner cover. NOTE: Refer to «Fastener Notice»(ref-238188-S13145861262006072400000) in Cautions and Notices.
3. Tighten the air cleaner cover screws until snug.
4. Install the outlet resonator to the MAT/IAT sensor.
5. Tighten the air cleaner outlet duct clamp at the MAF/IAT sensor. Tighten: Tighten the clamp to 4 N.m (35 lb in).

Scheme 379

1. Loosen the air cleaner outlet resonator clamp at the mass air flow/intake air temperature (MAF/IAT) sensor.
2. Remove the outlet resonator from the MAT/IAT sensor.
3. Disconnect the MAF/IAT sensor electrical connector (4).
4. Remove the air cleaner by pulling upward until the mounting studs are free from the grommets.

1. Install the air cleaner by pressing downward until the grommets are seated.
2. Connect the MAF/IAT sensor electrical connector (4).
3. Install the outlet resonator to the MAT/IAT sensor. NOTE: Refer to «FASTENER NOTICE»(ref-246412-S41332073762006122100000) in Cautions and Notices.
4. Tighten the air cleaner outlet duct clamp at the MAF/IAT sensor. Tighten: Tighten the clamp to 4 N.m (35 lb in).

Scheme 380

Scheme 381

Scheme 382

1. Loosen the air cleaner outlet resonator clamp at the mass air flow/intake air temperature (MAF/IAT) sensor.
2. Separate the duct from the MAF/IAT sensor.
3. Remove the air cleaner outlet resonator wing nut.
4. Remove the air cleaner outlet resonator from the throttle body by pivoting the resonator upward until the hinge clip releases from the lip on the throttle body.
5. Remove the air cleaner outlet resonator.

1. Install the air cleaner outlet resonator.
2. Align the hinge clip with the lip on the throttle body. Install the air cleaner outlet resonator to the throttle body by pivoting the resonator downward until the stud is through the hole in the resonator.
3. Install the air cleaner outlet resonator wing nut.
4. Install the air cleaner outlet resonator to the MAF/IAT sensor. NOTE: Refer to «Fastener Notice»(ref-238188-S13145861262006072400000) in Cautions and Notices.
5. Tighten the air cleaner outlet duct clamp at the MAF/IAT sensor. Tighten: Tighten the clamp to 4 N.m (35 lb in).